Tufted fibrous web

ABSTRACT

Disclosed is a fibrous web comprising a first region and at least one discrete integral second region, the second region having at least one portion being a discontinuity exhibiting a linear orientation and defining a longitudinal axis, and at least another portion being a deformation comprising a plurality of tufted fibers integral with but extending from the first region.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of prior copendingU.S. application Ser. No. 10/435,996, filed May 12, 2003, which is acontinuation-in-part of prior copending U.S. application Ser. No.10/324,661, filed Dec. 20, 2002.

FIELD OF INVENTION

[0002] This invention relates to fibrous webs such as woven and nonwovenwebs. In particular, this invention relates to fibrous webs treated bymechanical formation to have increased softness or bulk properties.

BACKGROUND OF THE INVENTION

[0003] Fibrous webs are well known in the art. For example, woven webssuch as textile and knit fabrics are well known as material forclothing, upholstery, drapes, and the like. Also, nonwoven webs such aswebs formed from polymer fibers are well known as materials useful fordisposable products such as facing layers on absorbent articles such asdiapers, for example.

[0004] In many applications it is desirable that fibrous webs have abulky texture and/or softness. For example, textile wovens known asterry cloth have a bulky texture and softness and are often used forbath towels, wiping cloths, bibs, clothing, and upholstery fabric. Terrycloth is woven on specially made weaving machines, such as rapierweaving machines. Terry cloth is characterized by tufted loops ofthread, and the tufts can be varied in number and density of loops.However, terry cloth is relatively expensive due to the relativelycomplex and expensive weaving machines necessary for its manufacture.The expense of terry cloth makes it commercially unfeasible for manyapplications, particularly for articles intended for limited use, suchas disposable absorbent articles.

[0005] Attempts have been made to produce a nonwoven fabric having theappearance of terry cloth. For example, U.S. Pat. No. 4,465,726 and U.S.Pat. No. 4,379,799, both to Holmes et al., describe an apertured, ribbedterry cloth-like nonwoven fabric produced by fluid entangling of fiberson a special forming belt. Even if apertures could be avoided in themethod disclosed in Holmes et al., it is well known that fluidentangling is a relatively expensive process for manufacture of nonwovenwebs, particularly for webs intended for disposable article use.Furthermore, webs formed by fluid entangling typically have beensubjected to forces of the fluid in all the regions of the web so thatthe entire web is subjected to the applied mechanical energy of thefluid forces.

[0006] Accordingly, there is a need for a low cost fibrous web havingterry cloth-like properties.

[0007] Additionally, there is a need for a method for relativelyinexpensively making a fibrous web having terry cloth-like properties.

[0008] Further, there is a need for a low cost method of making a soft,porous web of woven or nonwoven material.

SUMMARY OF THE INVENTION

[0009] A fibrous web having a first surface and a second surface isdisclosed. The web comprises a first region and a plurality of discreteintegral second regions, the second regions having at least one portionbeing a discontinuity exhibiting a linear orientation and defining alongitudinal axis, and at least another portion being a deformationcomprising a plurality of tufted fibers integral with but extending fromthe first region.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a perspective view of a web of the present invention.

[0011]FIG. 2 is an enlarged view of a portion of the web shown in FIG.1.

[0012]FIG. 3 is a cross-sectional view of section 3-3 of FIG. 2.

[0013]FIG. 4 is a plan view of a portion of the web as indicated by 4-4in FIG. 3.

[0014]FIG. 5 is a photomicrograph of a portion of a web of the presentinvention.

[0015]FIG. 6 is a photomicrograph of a portion of the web of FIG. 5.

[0016]FIG. 7 is a perspective view of an apparatus for forming the webof the present invention.

[0017]FIG. 8 is a cross-sectional depiction of a portion of theapparatus shown in FIG. 7.

[0018]FIG. 9 is a perspective view of a portion of the apparatus forforming one embodiment the web of the present invention.

[0019]FIG. 10 is an enlarged perspective view of a portion of theapparatus for forming the web of the present invention.

[0020]FIG. 11 is a photomicrograph of a portion of a web of the presentinvention.

[0021]FIG. 12 is a photomicrograph of a portion of a web of the presentinvention.

[0022]FIG. 13 is a photomicrograph of a portion of a web of the presentinvention.

[0023]FIG. 14 is a photomicrograph of a portion of a web of the presentinvention.

[0024]FIG. 15 is a photomicrograph of a portion of a web of the presentinvention.

[0025]FIG. 16 is a photomicrograph of a portion of a web of the presentinvention.

[0026]FIG. 17 is a photomicrograph of a portion of a web of the presentinvention.

[0027]FIG. 18 is a schematic representation of a portion of a web of thepresent invention.

[0028]FIG. 19 is another schematic representation of a portion of a webof the present invention.

[0029]FIG. 20 is another schematic representation of a portion of a webof the present invention

[0030]FIG. 21 is a photomicrograph of a portion of a web of the presentinvention.

[0031]FIG. 22 is an enlarged photograph of a portion of the web shown inFIG. 18.

[0032]FIG. 23 is a partial cut away plan view of a sanitary napkin ofthe present invention.

[0033]FIG. 24 is a partial cut away perspective view of a tampon of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

[0034]FIG. 1 shows a web 1 of the present invention. Web 1 is formedfrom a generally planar, two dimensional nonwoven precursor web 20(shown below with respect to the method of making) having a firstsurface 12 and a second surface 14, and having a machine direction (MD)and a cross machine direction (CD) as is commonly known in the art ofnonwoven webs. First surface 12 corresponds to first “side” of web 1 andsecond surface 14 corresponds to the second “side” of web 1, the term“sides” being used in the common usage of generally two-dimensionalwebs, such as paper and films. Although the present invention can bepracticed with woven webs, in a preferred embodiment precursor web 20 isa nonwoven web and is comprised of substantially randomly orientedfibers, that is, randomly oriented at least with respect to the MD andCD. By “substantially randomly oriented” is meant that, due toprocessing conditions, there may be a higher amount of fibers orientedin the MD than the CD, or vice-versa. For example, in spunbonding andmeltblowing processes, continuous strands of fibers are deposited on asupport moving in the MD. Despite attempts to make the orientation ofthe fibers of the spunbond or meltblown nonwoven web “random,” usually ahigher percentage of fibers are oriented in the MD as opposed to the CD.

[0035] Nonwoven precursor webs 20 can be any known nonwoven webscomprising fibers having sufficient elongation properties to be formedinto web 1 as described more fully below. As shown in FIG. 2, web 1 hasa first region 2 defined on both sides of web 1 by the generally planar,two-dimensional configuration of the precursor web 20, and a pluralityof discrete second regions 4 defined by spaced-apart deformations 6 anddiscontinuities 16 which result from integral extensions of the fibersof the precursor web 20. The structure of second regions 4 isdifferentiated depending on which side of web 1 is considered. For theembodiment of web 1 shown in FIG. 1, on the side of web 1 associatedwith first surface 12 of web 1, second region 4 comprises deformations6, each deformation 6 comprising a plurality of tufted, looped, alignedfibers 8 extending outwardly from first surface 12. Deformations 6 canbe described as “tufts” of fibers, and each deformation 6 has a base 5proximal to the first surface 12, and a distal portion 3 at a maximumdistance from first surface 12, as shown in FIG. 3. On the side of web 1associated with second surface 14, second region 4 comprisesdiscontinuities 16 which are defined by fiber orientationdiscontinuities on second surface 14 of web 1. As shown below, in otherembodiments of web 1, the deformations 6 may be described as tufts, ortufted, but may not comprise looped or aligned fibers.

[0036] As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nothave randomly oriented fibers. Nonwoven webs or fabrics have been formedfrom many processes, such as, for example, meltblowing processes,spunbonding processes, hydroentangling processes, spunlacing processes,airlaying, and bonded carded web processes. The basis weight of nonwovenfabrics is usually expressed in grams per square meter (gsm) and thefiber diameters are usually expressed in microns. Fiber size can also beexpressed in denier. The basis weight of precursor web 20 can range from10 gsm to 500 gsm, depending on the ultimate use of the web 1. For useas a hand towel, for example, a basis weight of precursor web 20 ofbetween 25 gsm and 100 gsm may be appropriate. For use as a bath towel abasis weight of between 125 gsm and 250 gsm may be appropriate. For useas a ground cover, such as a cow carpet, a basis weight of between 350gsm and 500 gsm may be appropriate. The constituent fibers of nonwovenprecursor web 20 can be comprised of polymers such as polyethylene,polypropylene, polyester, and blends thereof. The fibers can comprisecellulose, rayon, cotton, or other natural materials or blends ofpolymers and natural materials. The fibers can also comprise a superabsorbent material such as polyacrylate or any combination of suitablematerials. The fibers can be monocomponent, bicomponent and/orbiconstituent, round, non-round fibers (e.g., shaped fibers or capillarychannel fibers), and can have major cross-sectional dimensions (e.g.,diameter for round fibers) ranging from 0.1-500 microns. For example,one type of fibers suitable for the nonwoven web includes nanofibers.Nanofibers are described as fibers having a mean diameter of less than 1micron. Nanofibers can comprise all of the fibers in a nonwoven web or aportion of the fibers in a nonwoven web. The constituent fibers of theprecursor web may also be a mixture of different fiber types, differingin such features as chemistry, components, diameter, shape, and thelike.

[0037] As used herein, “spunbond fibers” refers to small diameter fiberswhich are formed by extruding molten thermoplastic material as filamentsfrom a plurality of fine, usually circular capillaries of a spinneretwith the diameter of the extruded filaments then being rapidly reduced.Spunbond fibers are generally not tacky when they are deposited on acollecting surface. Spunbond fibers are generally continuous and haveaverage diameters (from a sample of at least 10) larger than 7 microns,and more particularly, between about 10 and 40 microns.

[0038] As used herein, the term “meltblowing” refers to a process inwhich fibers are formed by extruding a molten thermoplastic materialthrough a plurality of fine, usually circular, die capillaries as moltenthreads or filaments into converging high velocity, usually heated, gas(for example air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface,often while still tacky, to form a web of randomly dispersed meltblownfibers. Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally smaller than 10 microns in averagediameter.

[0039] As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. In addition, unless otherwise specificallylimited, the term “polymer” includes all possible geometricconfigurations of the material. The configurations include, but are notlimited to, isotactic, atactic, syndiotactic, and random symmetries.

[0040] As used herein, the term “monocomponent” fiber refers to a fiberformed from one or more extruders using only one polymer. This is notmeant to exclude fibers formed from one polymer to which small amountsof additives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

[0041] As used herein, the term “bicomponent fibers” refers to fiberswhich have been formed from at least two different polymers extrudedfrom separate extruders but spun together to form one fiber. Bicomponentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebicomponent fibers and extend continuously along the length of thebicomponent fibers. The configuration of such a bicomponent fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement, each as is known inthe art of multicomponent, including bicomponent, fibers. Bicomponentfibers can be splittable fibers, such fibers being capable of beingsplit lengthwise before or during processing into multiple fibers eachhaving a smaller cross-sectional dimension than the original bicomponentfiber. Splittable fibers have been shown to produce softer nonwoven websdue to their reduced cross-sectional dimensions. Representativesplittable fibers useful in the present invention include type T-502 andT-512 16 segment PET/nylon 6 2.5 denier fibers; and type T-522 16segment PET/PP splittable fibers, all available from Fiber InnovationTechnology, Johnson City, Tenn.

[0042] As used herein, the term “biconstituent fibers” refers to fiberswhich have been formed from at least two polymers extruded from the sameextruder as a blend. Biconstituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Biconstituent fibers are sometimes also referred to as multiconstituentfibers.

[0043] As used herein, the term “non-round fibers” describes fibershaving a non-round cross-section, and includes “shaped fibers” and“capillary channel fibers.” Such fibers can be solid or hollow, and theycan be tri-lobal, delta-shaped, and are preferably fibers havingcapillary channels on their outer surfaces. The capillary channels canbe of various cross-sectional shapes such as “U-shaped”, “H-shaped”,“C-shaped” and “V-shaped”. One preferred capillary channel fiber isT-401, designated as 4 DG fiber available from Fiber InnovationTechnologies, Johnson City, Tenn. T-401 fiber is a polyethyleneterephthalate (PET polyester).

[0044] As used herein, the term “integral” as in “integral extension”when used of the second regions 4 refers to fibers of the second regions4 having originated from the fibers of the precursor web 20. Therefore,the looped fibers 8 of deformations 6, for example, can be plasticallydeformed and extended fibers of the precursor web 20, and are,therefore, integral with first regions 2 of web 1. As used herein,“integral” is to be distinguished from fibers introduced to or added toa separate precursor web for the purpose of making tufts, as is commonlydone in conventional carpet making, for example. It can be appreciatedthat a suitable nonwoven web 20 should comprise fibers capable ofexperiencing sufficient plastic deformation and tensile elongation, orare capable of sufficient fiber mobility such that looped fibers 8 areformed. However, it is recognized that a certain percentage of fibersurged out of the plane of the first surface 12 of the precursor web 20will not form a loop, but instead will break and form loose ends. Suchfibers are referred to herein as “loose” or “broken” fibers 18 as shownin FIG. 3. Loose fiber ends 18 can also be the result of formingdeformations 6 from nonwoven webs consisting of or containing cut staplefibers. Loose fiber ends 18 are not necessarily undesirable for thepresent invention, but it is believed that web 1 can retain its bulkyand soft character more readily when deformation 6 comprises primarilylooped fibers 8. In a preferred embodiment, at least about 50%, morepreferably at least 70%, and most preferably at least 90% of fibersurged in the Z-direction are looped fibers 8.

[0045] A representative deformation 6 for the embodiment of web 1 shownin FIG. 1 is shown in a further enlarged view in FIG. 2. As shown,deformation 6 comprises a plurality of looped fibers 8 that aresubstantially aligned such that deformation 6 has a distinctlongitudinal orientation and a longitudinal axis L. Deformations 6 alsohave a transverse axis T generally orthogonal to longitudinal axis L inthe MD-CD plane. In the embodiment shown in FIGS. 1 and 2, longitudinalaxis L is parallel to the MD. In one embodiment, all the spaced apartdeformations 6 have generally parallel longitudinal axes L. The numberof deformations 6 per unit area of web 1, i.e., the area density ofdeformations 6, can be varied from 1 deformation 6 per square centimeterto as high as 100 deformations 6 per square centimeter. There can be atleast 10, or at least 20 deformations 6 per square centimeter, dependingon the end use. In general, the area density need not be uniform acrossthe entire area of web 1, but deformations 6 can be only in certainregions of web 1, such as in regions having predetermined shapes, suchas lines, stripes, bands, circles, and the like.

[0046] As shown in FIG. 2, and more clearly in FIGS. 3 and 4, onecharacteristic of the fibers 8 of deformations 6 in one embodiment ofweb 1 is the predominant directional alignment of the looped fibers 8.As shown in FIGS. 3 and 4, the looped fibers 8 have a substantiallyuniform alignment with respect to transverse axis T when viewed in planview, such as in FIG. 4. By “looped” fibers 8 is meant that fibers 8begin and end in web 1. By “aligned” with respect to looped fibers 8 ofdeformations 6 is meant that looped fibers 8 are all generally orientedsuch that, if viewed in plan view as in FIG. 4, each of the loopedfibers 8 has a significant vector component parallel to the transverseaxis T, and preferably a major vector component parallel to thetransverse axis T. As used herein, a looped fiber 8 oriented at an angleof greater than 45 degrees from the longitudinal axis L when viewed inplan view, as in FIG. 4, has a significant vector component parallel tothe transverse axis T. As used herein, a looped fiber 8 oriented at anangle of greater than 60 degrees from longitudinal axis L when viewed inplan view, as in FIG. 4, has a major vector component parallel to thetransverse axis T. In a preferred embodiment, at least 50%, morepreferably at least 70%, and more preferably at least 90% of fibers 8 ofdeformation 6 have a significant, and more preferably, a major vectorcomponent parallel to transverse axis T. Fiber orientation can bedetermined by use of magnifying means if necessary, such as a microscopefitted with a suitable measurement scale. In general, for a non-linearsegment of fiber viewed in plan view, a straight-line approximation forboth longitudinal axis L and the looped fibers 8 can be used fordetermining the angle of looped fibers 8 from longitudinal axis L.

[0047] The orientation of looped fibers 8 in the deformations 6 ofsecond region 4 is to be contrasted with the fiber composition andorientation of the first region 2, which, for nonwoven precursor webs 20is best described as having a substantially randomly-oriented fiberalignment. In a woven web embodiment, the orientation of the loopedfibers 8 in deformations 6 could be the same as described above, but thefibers of second region 2 would have the orientation associated with theparticular weaving process used to make the web, e.g., a square weavepattern.

[0048] In the embodiment shown in FIG. 1 the longitudinal axes L ofdeformations 6 are generally aligned in the MD. Deformations 6 and,therefore, longitudinal axes L, can, in principle, be aligned in anyorientation with respect to the MD or CD. Therefore, in general, it canbe said that for each deformation 6, the looped aligned fibers 8 arealigned generally orthogonal to the longitudinal axis L such that theyhave a significant vector component parallel to transverse axis T, andmore preferably a major vector component parallel to transverse axis T.

[0049]FIG. 5 is a scanning electron microscope (SEM) photo of a web 1similar to that described with respect to FIG. 1. The web 1 of FIG. 5 isa 70 gsm spunbond nonwoven web comprising polyethylene/polypropylene(sheath/core) bicomponent fibers. The perspective of FIG. 5 isessentially a side view of the first surface 2 and deformations 6 of web1. By “side view” is meant that the photo of FIG. 5 is taken generallyin the CD direction as indicated in FIGS. 1-4, such that the MD andlongitudinal axes L of each deformation 6 are oriented across (e.g.,generally horizontally) in FIG. 5. As shown in FIG. 5, deformations 6comprise looped aligned fibers 8 are aligned generally orthogonal to thelongitudinal axis L and have at least a significant vector componentparallel to transverse axis T.

[0050] In some embodiments, due to the preferred method of formingdeformations 6, as described below, another characteristic ofdeformations 6 is their generally open structure characterized by openvoid area 10 defined interiorly of deformations 6, as shown in FIG. 3.The void area 10 may have a shape that is wider or larger at the distal3 end of deformation 6 and narrower at the base 5 of the deformation 6.This shape is opposite to the shape of the tooth which is used to formthe deformation 6. By “void area” is not meant completely free of anyfibers, but is meant as a general description of its general appearance.Therefore, it may be that in some deformations 6 a loose fiber 8 or aplurality of loose fibers 8 may be present in the void area 10. By“open” void area is meant that the two longitudinal ends of deformation6 are generally open and free of fibers, such that deformation 6 formssomething like a “tunnel” structure, as shown in FIG. 3. For example,FIG. 6 is a close-up SEM view of one deformation 6 of the web 1 shown inFIG. 5. As shown, in addition to the looped aligned fibers 8 there is adistinct open void area 10 defined by a plurality of looped alignedfibers 8. Very few broken fibers 18 are visible. As can be seen, thebase 5 of the deformation 6 may be closed (as in the fibers forming thedeformation 6 are close enough together to touch) or may remain open.Generally, any opening at the base 6 is narrow.

[0051] Additionally, as a consequence of a preferred method of makingweb 1, the second regions 4 associated with second surface 14 arediscontinuities 16 characterized by a generally linear indentationdefined by formerly random fibers of the second surface 14 having beenurged directionally (i.e., the “Z -direction” as is commonly understoodin the nonwoven art to indicate an “out-of-plane” direction generallyorthogonal to the MD-CD plane as shown in FIGS. 1 and 3) intodeformation 6 by the teeth of the forming structure, described in detailbelow. The abrupt change of orientation exhibited by the previouslyrandomly-oriented fibers of precursor web 20 defines the discontinuity16, which exhibits a linearity such that it can be described as having alongitudinal axis generally parallel to longitudinal axis L of thedeformation 6. Due to the nature of many nonwoven webs useful asprecursor webs 20, discontinuity 16 may not be as distinctly noticeableas deformations 6. For this reason, the discontinuities 16 on the secondside of web 1 can go unnoticed and may be generally undetected unlessweb 1 is closely inspected. Thus in some embodiments, web 1 has the lookand feel of terry cloth on a first side, and a relatively smooth, softlook and feel on a second side. In other embodiments, discontinuities 16can appear as apertures, and may be apertures through web 1 via the endsof the tunnel-like looped deformations 6.

[0052] Further, as a consequence of a preferred method of making web 1,whether or not the second regions 4 have looped aligned fibers 8, eachexhibits a pronounced linearity at or near the first and second surfaces12, and 14, respectively, of web 1. As disclosed more fully below withrespect to the method of making, one can appreciate that, due to thegeometry of teeth 110 of roll 104, the second regions 4 of precursor web20 each have a linear orientation associated therewith. This linearorientation is an inevitable consequence of the method of making web 1as described herein. One way of understanding this linear orientation isto consider the linear orientation of discontinuities 16 on the secondsurface 14 of web 1. Likewise, if deformation 6 were removed from web 1at first surface 12, the second region 4 would appear as a lineardiscontinuity on the first surface 12 of web 1, e.g., as if a linearslit or cut had been made in precursor web 20 at the location ofdeformation 6. This linear web discontinuity corresponds directionallyto longitudinal axis L.

[0053] From the description of web 1, it can be seen that the loopedfibers 8 of deformation 6 can originate and extend from either the firstsurface 12 or the second surface 14 of web 1. Of course the fibers 8 ofdeformation 6 can also extend from the interior 19 of web 1. The fibers8 of deformations 6 extend due to having been urged out of the generallytwo-dimensional plane of precursor web 20 (i.e., urged in the “Z-direction” as shown in FIG. 3). In general, the fibers 8 or 18 of thesecond regions 4 comprise fibers that are integral with and extend fromthe fibers of the fibrous web first regions 2.

[0054] Therefore, from the above description, it is understood that inone embodiment web 1 can be described as being a fibrous web 1 having afirst surface 12 and a second surface 14, the fibrous web 1 comprising afirst region 2 and a plurality of discrete integral second regions 4,the second regions 4 having at least one portion being a discontinuity16 exhibiting a linear orientation and defining a longitudinal axis Land at least another portion being a deformation 6 comprising aplurality of tufted fibers integral with but extending from the firstregion 2.

[0055] The extension of looped fibers 8 can be accompanied by a generalreduction in fiber cross sectional dimension (e.g., diameter for roundfibers) due to plastic deformation of the fibers and the effects ofPoisson's ratio. Therefore, the fibers 8 of deformation 6 can have anaverage fiber diameter less than the average fiber diameter of thefibers of precursor web 20 as well as the fibers of first regions 2. Itis believed that this reduction in fiber diameter contributes to theperceived softness of the web 1, a softness that can be comparable tocotton terry cloth, depending on the material properties of theprecursor web 20. It has been found that the reduction in fibercross-sectional dimension is greatest intermediate the base 5 and thedistal portion 3. This is believed to be due to the method of making, asdisclosed more fully below. Briefly, it is believed that portions offibers at the base 5 and distal portion 3 of deformations 6 are adjacentthe tip of teeth 110 of roll 104, described more fully below, and arefrictionally locked and immobile during processing. Thus, theintermediate portions of deformations 6 are more free to stretch, orelongate, and accordingly, are more free to experience a correspondingfiber cross sectional dimension reduction.

[0056] Referring to FIG. 7 there is shown in an apparatus and method formaking web 1 of the present invention. The apparatus 100 comprises apair of intermeshing rolls 102 and 104, each rotating about an axis A,the axes A being parallel in the same plane. Roll 102 comprises aplurality of ridges 106 and corresponding grooves 108 which extendunbroken about the entire circumference of roll 102. Roll 104 is similarto roll 102, but rather than having ridges that extend unbroken aboutthe entire circumference, roll 104 comprises a plurality of rows ofcircumferentially-extending ridges that have been modified to be rows ofcircumferentially-spaced teeth 110 that extend in spaced relationshipabout at least a portion of roll 104. The individual rows of teeth 110of roll 104 are separated by corresponding grooves 112. In operation,rolls 102 and 104 intermesh such that the ridges 106 of roll 102 extendinto the grooves 112 of roll 104 and the teeth 110 of roll 104 extendinto the grooves 108 of roll 102. The intermeshing is shown in greaterdetail in the cross sectional representation of FIG. 8, discussed below.Both or either of rolls 102 and 104 can be heated by means known in theart such as by using hot oil filled rollers or electrically-heatedrollers.

[0057] In FIG. 7, the apparatus 100 is shown in a preferredconfiguration having one patterned roll, e.g., roll 104, and onenon-patterned grooved roll 102. However, in certain embodiments it maybe preferable to use two patterned rolls 104 having either the same ordiffering patterns, in the same or different corresponding regions ofthe respective rolls. Such an apparatus can produce webs withdeformations protruding from both sides of the web 1.

[0058] The method of making a web 1 of the present invention in acommercially viable continuous process is depicted in FIG. 7. Web 1 ismade by mechanically deforming a precursor web 20 that can be describedas generally planar and two-dimensional. By “planar” and “twodimensional” is meant simply that the web is flat relative to thefinished web 1 that has distinct, out-of-plane, Z-directionthree-dimensionality imparted due to the formation of second regions 4.“Planar” and “two-dimensional” are not meant to imply any particularflatness, smoothness or dimensionality.

[0059] The process described is similar in many respects to a process asdescribed in U.S. Pat. No. 5,518,801 entitled “Web Materials ExhibitingElastic-Like Behavior” and referred to in subsequent patent literatureas “SELF” webs, which stands for “Structural Elastic-like Film”.However, there are significant differences between the apparatus of thepresent invention and the apparatus disclosed in the above-identified'801 patent. These differences account for the novel features of the webof the present invention. As described below, the teeth 110 of roll 104have a specific geometry associated with the leading and trailing edgesthat permit the teeth, e.g., teeth 110, to essentially “punch” throughthe precursor web 20 as opposed to, in essence, emboss the web. Thedifference in the apparatus 100 of the present invention results in afundamentally different web. For example, a web 1 of the presentinvention can have distinctive “tunnel-like” tufted deformations 6 oflooped, aligned fibers 8, unlike the “tent-like” rib-like elements ofprior art SELF webs which each have continuous side walls associatedtherewith, i.e., a continuous “transition zone.” It is believed that thedistinctive “tunnel-like” tufted deformations 6 of the web 1 of thepresent invention contribute to the superior fluid handling propertiesof web 1 by permitting fluid entry into and through web 1 via voidregions 10 of deformations 6.

[0060] Precursor web 20 is provided either directly from a web makingprocess or indirectly from a supply roll (neither shown) and moved inthe machine direction to the nip 116 of counter-rotating intermeshingrolls 102 and 104. Precursor web can be a nonwoven web comprising any ofknown fiber types, including bicomponent fibers, capillary channelfibers, microfibers or splittable fibers. Precursor web 20 can bepreheated by means known in the art, such as by heating over oil-heatedrollers. Furthermore, precursor web can be a nonwoven web made by knownprocesses, such as meltblown, spunbond, and carded. As precursor web 20goes through the nip 116 the teeth 110 of roll 104 enter grooves 108 ofroll 102 and simultaneously urge fibers out of the plane of plane ofprecursor web 20 to form second regions 2, including deformations 6 anddiscontinuities 16. In effect, teeth 110 “push” or “punch” throughprecursor web 20. As the tip of teeth 110 push through precursor web 20the portions of fibers that are oriented predominantly in the CD andacross teeth 110 are urged by the teeth 110 out of the plane ofprecursor web 20 and are stretched, pulled, and/or plastically deformedin the Z-direction, resulting information of second region 4, includingthe looped fibers 8 of deformations 6 of web 1. Fibers that arepredominantly oriented generally parallel to the longitudinal axis L,i.e., in the machine direction of precursor web 20 as shown in FIG. 1,are simply spread apart by teeth 110 and remain substantially in thefirst region 2 of web 1. Although, as discussed more fully below, it hasbeen found that the rate of formation of deformations 6 affects fiberorientation, in general, and at least at low rates of formation, it canbe understood why the looped fibers 8 can exhibit the unique fiberorientation which is a high percentage of fibers having a significant ormajor vector component parallel to the transverse axis T of deformation6, as discussed above with respect to FIGS. 3 and 4. In general, atleast some of the fibers of deformation 6 are looped, aligned fibers 8which can be described as having a significant or major vector componentparallel to a Z-oriented plane orthogonal to transverse axis T.

[0061] The number, spacing, and size of deformations 6 can be varied bychanging the number, spacing, and size of teeth 110 and makingcorresponding dimensional changes as necessary to roll 104 and/or roll102. This variation, together with the variation possible in precursorwebs 20 and line speeds, permits many varied webs 1 to be made for manypurposes. For example, web 1 made from a high basis weight textilefabric having MD and CD woven extensible threads could be made into asoft, porous ground covering, such as a cow carpet useful for reducingudder and teat problems in cows. A web 1 made from a relatively lowbasis weight nonwoven web of extensible spunbond polymer fibers could beused as a terry cloth-like fabric for semi-durable or durable clothing.As described more fully below, web 1 can also be used in disposableabsorbent articles.

[0062]FIG. 8 shows in cross section a portion of the intermeshing rolls102 and 104 including ridges 106 and teeth 110. As shown teeth 110 havea tooth height TH (note that TH can also be applied to ridge 106 height;in a preferred embodiment tooth height and ridge height are equal), anda tooth-to-tooth spacing (or ridge-to-ridge spacing) referred to as thepitch P. As shown, depth of engagement E is a measure of the level ofintermeshing of rolls 102 and 104 and is measured from tip of ridge 106to tip of tooth 110. The depth of engagement E, tooth height TH, andpitch P can be varied as desired depending on the properties ofprecursor web 20 and the desired characteristics of web 1. For example,in general, to obtain looped fibers in deformation 6, the greater thelevel of engagement E, the greater the necessary fiber mobility and/orelongation characteristics the fibers of precursor web 20 must possess.Also, the greater the density of second regions 4 desired (secondregions 4 per unit area of web 1), the smaller the pitch should be, andthe smaller the tooth length TL and tooth distance TD should be, asdescribed below.

[0063]FIG. 9 shows one embodiment of a roll 104 having a plurality ofteeth 110 useful for making a terry cloth-like web 1 of spunbondnonwoven material from a spunbond nonwoven precursor web 20 having abasis weight of between about 60 gsm and 100 gsm, preferably about 70gsm, or 80 gsm or 90 gsm. An enlarged view of teeth 110 shown in FIG. 9is shown in FIG. 10. In this embodiment of roll 104 teeth 110 have auniform circumferential length dimension TL of about 1.25 mm measuredgenerally from the leading edge LE to the trailing edge TE at the toothtip 111, and are uniformly spaced from one another circumferentially bya distance TD of about 1.5 mm. For making a terry-cloth web 1 from aprecursor web 20 having a basis weight in the range of about 60 to 100gsm, teeth 110 of roll 104 can have a length TL ranging from about 0.5mm to about 3 mm and a spacing TD from about 0.5 mm to about 3 mm, atooth height TH ranging from about 0.5 mm to about 10 mm, and a pitch Pbetween about 1 mm (0.040 inches) and 2.54 mm (0.100 inches). Depth ofengagement E can be from about 0.5 mm to about 5 mm (up to a maximumapproaching the tooth height TH). Of course, E, P, TH, TD and TL caneach be varied independently of each other to achieve a desired size,spacing, and area density of deformations 6 (number of deformations 6per unit area of web 1).

[0064] As shown in FIG. 8, each tooth 110 has a tip 111, a leading edgeLE and a trailing edge TE. The tooth tip 111 is elongated and has agenerally longitudinal orientation, corresponding to the longitudinalaxes L of second regions 4. It is believed that to get the tufteddeformations 6 of the web 1 that can be described as being terrycloth-like, the LE and TE should be very nearly orthogonal to the localperipheral surface 120 of roll 104. As well, the transition from the tip111 and the LE or TE should be a sharp angle, such as a right angle,having a sufficiently small radius of curvature such that, in use theteeth 110 push through precursor web 20 at the LE and TE. Without beingbound by theory, it is believed that having relatively sharply angledtip transitions between the tip of tooth 110 and the LE and TE permitsthe teeth 110 to punch through precursor web 20 “cleanly”, that is,locally and distinctly, so that the resulting web 1 can be described as“tufted” in second regions 4 rather than “embossed” for example. When soprocessed, the web 1 is not imparted with any particular elasticity,beyond what the precursor web 20 may have possessed originally.

[0065] It has been found that line speed, that is, the rate at whichprecursor web 20 is processed through the nip of rotating rolls 102 and104, and the resulting rate of formation of deformations 6, impacts thestructure of the resulting deformations 6. For example, the deformations6 shown in FIGS. 5 and 6 were made at a relatively low rate ofapproximately 3 meters per minute (m/min) (about 10 feet per minute).Three m/min is considered a relatively slow rate for commercialproduction for many consumer applications, but for the spunbondbicomponent fibers used in the nonwoven web shown in FIGS. 5 and 6 thisrelatively slow speed resulted in very uniform, looped, aligned fibers 8in deformations 6.

[0066] At higher line speeds, i.e., relatively higher rates ofprocessing through the nip of rotating rolls 102 and 104, like materialscan exhibit very different structures for deformations 6, i.e., tufts.For example, FIGS. 11 and 12 show representative deformations 6 for webs1 made from the same material with the same process conditions, the onlydifference being the rotational speed of the rolls 102 and 104, i.e.,line speed (in units of length/time) of the precursor web 20 beingprocessed into web 1. The precursor web 20 used for each of the websshown in FIGS. 11 and 12 was a 25 gsm nonwoven web comprisingpolypropylene and available from BBA Nonwovens, Simpsonville, S.C., andsold under the trade name Sofspan 200®. The web shown in FIG. 11 wasprocessed through the nip 116 of rolls 102 and 104 having a depth ofengagement E of about 3.4 mm (about 0.135 inch), a pitch P of about 1.5mm (about 0.060 inch), a tooth height TH, of about 3.7 mm (about 0.145inch), a tooth distance of TD of 1.6 mm (abut 0.063 inch), and a toothlength of TL of about 1.25 mm (about 0.050 inch). The web was run at aline speed of about 15 meters/minute (about 50 feet per minute). The webshown in FIG. 12 is identical to the web shown in FIG. 11, and wasprocessed under identical conditions except for the line speed, whichwas about 150 meters per minute (about 500 feet per minute).

[0067] As can be seen from an inspection of FIGS. 11 and 12, thedeformations 6 shown are noticeably different. The deformation 6 shownin FIG. 11 is similar in structure to the deformations shown in FIGS.1-6. That is, it exhibits substantially aligned, looped fibers 8 withvery few broken fibers, e.g., fibers 18 as shown in FIG. 3. Thedeformation 6 shown in FIG. 12, however, exhibits a very differentstructure, a structure that appears to be typical of spunbond nonwovenmaterials processed to form deformations 6 at relatively high speeds.Typical of this structure is broken fibers between the proximal portion,i.e., base 5, of deformations 6 and the distal portion, i.e., the top 3,of deformations 6, and what appears to be a “mat” 7 of fibers at the topof the deformation 6. Mat 7 comprises and is supported at the top ofdeformations 6 by unbroken, looped fibers 8, and also comprises portionsof broken fibers 11 that are no longer integral with precursor web 20.That is, mat 7 comprises fiber portions which were formerly integralwith precursor web 20 but which are completely detached from precursorweb 20 after processing at sufficiently high line speeds in the processdescribed with reference to FIGS. 7 and 8.

[0068] Therefore, from the above description, it is understood that inone embodiment web 1 can be described as being a fibrous web 1 having afirst surface 12 and a second surface 14, the fibrous web 1 comprising afirst region 2 and a plurality of discrete second regions 4, the secondregions 4 having at least one portion being a discontinuity 16exhibiting a linear orientation and defining a longitudinal axis L andat least another portion being a deformation 6, the deformation 6comprising fibers integral with but extending from first region 2 andfibers neither integral with nor extending from first region 2.

[0069] Another example of webs 1 being identical in material andprocessing except for line speed is shown with respect to FIGS. 13 and14. The precursor web 20 for each web 1 shown in FIGS. 13 and 14 was a60 gsm spunbond nonwoven web available from BBA Nonwovens, Simpsonville,S.C., and sold under the trade name Sofspan 200®. The web shown in FIG.13 was processed through the nip 116 of rolls 102 and 104 having a depthof engagement E of about 3.4 mm (about 0.135 inch), a pitch P of about1.5 mm (about 0.060 inch), a tooth height TH, of about 3.7 mm (about0.145 inch), a tooth distance of TD of about 1.6 mm (about 0.063 inch),and a tooth length of TL of about 1.25 mm (about 0.050 inch). The webwas run at a line speed of about 15 meters/minute (about 50 feet perminute). The web shown in FIG. 14 is identical to the web shown in FIG.13, and was processed under identical conditions except for the linespeed, which was about 150 meters per minute (about 500 feet perminute).

[0070] The web 1 shown in FIG. 13 was processed at a line speed of about15 meters per minute (about 50 feet per minute). As shown, even at thisrelatively moderate line speed, some amount of matting at the distal endof deformation 6 is noticed. This matting, which appears to be a higherdensity of flattened, compressed fiber portions, occurs on the portionof deformation 6 associated during manufacturing with the tip of tooth110 of roll 104. As line speed is increased, this matting, i.e., mat 7,becomes more distinct, as shown in FIG. 14, which shows a web processedunder identical conditions as the web shown in FIG. 13, but wasprocessed at a line speed of about 150 meters per minute (about 500 feetper minute). The deformations 6 shown in FIG. 14 exhibit a more distinctmat 7 and can be described as comprising fibers 8 or 18 integral withbut extending from first region 2 and fibers 11 (in mat 7) which areneither integral with nor extending from first region 2.

[0071] It is believed that the distinct fiber orientation observed atthe distal portion of deformations 6, e.g., mat 7, is due primarily toprocessing rates, it is also believed to be affected by otherparameters, such as fiber type and basis weight of the precursor web 20as well as processing temperatures that can affect the degree offiber-to-fiber bonding. For example, as observed above, matting offibers occurs on the portion of deformation 6 associated duringmanufacturing with the tip of tooth 110 of roll 104. It is believed thatfrictional engagement of the fibers at the tip of the teeth “lock” thefibers in place, thereby limiting fiber elongation and/or fibermobility, two mechanisms believed to permit formation of deformations 6.Therefore, once locked, so to speak, in position, fibers adjacent tooth110 tip can be broken, and, due to the random entanglement of theprecursor web as well as possible cold welding of fibers due to pressureand friction, the broken fibers 11 become and remain lodged in mat 7 atthe distal end 3 of deformations 6.

[0072] Precursor webs 20 having relatively higher basis weightsgenerally have relatively more fiber 11 portions in mat 7. In one sense,it appears as is most of the fiber content of the precursor web 20 inthe immediate vicinity of a tooth tip 110 during manufacture is simplydisplaced in the Z-direction to the distal portion 3 of deformations 6,resulting in mat 7. Precursor webs 20 comprising relatively lowelongation fibers, or fibers with relatively low fiber-to-fiber mobility(e.g., relatively limited capability for fiber reptation) appear toresult in relatively few fibers becoming and remaining lodged in mat 7at the distal end 3 of deformations 6. Fiber-to-fiber mobility can beincreased by reducing or eliminating the fiber-to-fiber bonds. Thermalbonds can be completely eliminated, or significantly reduced in certainnonwoven webs to increase fiber-to-fiber mobility. Similarly,hydroentangled web can be less entangled to increase fiber-to-fibermobility. For any precursor web 20 lubricating it prior to processing asdisclosed herein can also increase fiber-to-fiber mobility. For example,a mineral oil lubricant can be applied to precursor web 20 prior to itentering the nip 116 of rolls 102 and 104.

[0073] The result of the presence of mats 7 is a web 1 having a slightlyrougher, textured impression on one side thereof, useful, for example,for wipes in which more scrubbing texture is desirable. In one sense aweb having soft terry cloth-like tactile impression when made underrelatively low-speed processing conditions, can have the feel of a cheaphotel towel when processed under identical, but relatively higher linespeed conditions. This rough, textured tactile impression on a fibrousweb can be useful for some applications, such as for a hard surfacecleaning wipe or an exfoliating facial wipe.

[0074] It has been found that certain nonwoven webs, such as carded webscomprising staple-length fibers, produce very few looped fibers 8 indeformations 6, so that the deformations 6 produced in these webs cannotbe described as comprising a plurality of looped, aligned fibers 8 asdescribed above with respect to FIGS. 1-6. Instead, as shown in the SEMphotograph of FIG. 17, carded nonwoven webs can produce deformations 6having few, if any, looped, aligned fibers 8, and many, if not all,non-aligned fibers and/or broken fibers 18. The precursor web 20 used tomake the web 1 shown in FIG. 17 was a 40 gsm carded web available fromBBA Nonwovens, Simpsonville, S.C., as High Elongation Carded (HEC®) andwas processed through the nip 116 of rolls 102 and 104 having a depth ofengagement E of about 3.4 mm (about 0.135 inch), a pitch P of about 1.5mm (about 0.060 inch), a tooth height TH, of about 3.7 mm (about 0.145inch), a tooth distance of TD of about 1.6 mm (about 0.063 inch), and atooth length of TL of about 1.25 mm (about 0.050 inch). The web was runat a line speed of about 15 meters/minute (about 50 feet per minute). Itis believed that the non-alignment of fibers in deformations 6 made fromcarded webs is due in part to the nature of the fiber content of cardedwebs. Staple fibers are not “endless,” but instead have a predeterminedlength on the order of 25 mm to about 400 mm, and, more typically fromabout 40 mm to about 80 mm. Therefore, when a carded web is processed bythe apparatus described with respect to FIG. 7, it is believed thatthere is a much greater likelihood that a loose fiber end will be in thevicinity of a deformation 6 and thus produce a non-looped fiber end indeformation 6. Furthermore, often staple fibers do not have the sameelongation characteristics of spunbond or meltblown fibers, for example.However, even if deformations 6 have no looped fibers, the fibrous tuftsnevertheless provide a softness benefit and produce a web having terrycloth-like characteristics.

[0075] Therefore, from the above description, it is understood that theweb of the present invention need not have looped, aligned fibers, andin one embodiment can be described as being a fibrous web 1 formed byselective mechanical deformation of a precursor web 20 having a firstsurface 12 and a second surface 14 and comprising substantiallyrandomly-oriented fibers, the fibrous web comprising a first region ofsubstantially randomly-oriented fibers being substantially free ofdeformation by the selective mechanical deformation, and a plurality ofdiscrete integral second regions, the second regions 4 comprisingspaced-apart deformations 6 of the precursor web 20, each of the secondregions 4 having at least one portion being a discontinuity 16exhibiting a linearity and defining a longitudinal axis L and at leastanother portion comprising a plurality of tufted fibers integral withbut extending from said first region.

[0076] Webs 1 of the present invention offer many opportunities forproducing engineered materials having selected characteristics. Forexample, a web 1 can be made by selecting the length of staple fibers ina carded precursor web 20 so that the probability of having fiber endsexposed in deformations 6 can be reliably predicted. Also, a carded webof staple fibers can be blended or laminated with a spunbond nonwovenweb to produce a hybrid, such that the deformations 6 of second regions4 comprise primarily looped spunbond fibers and the first regions 2comprise both carded and spunbond fibers. The type of fibers, the lengthof staple fibers, the layering of fibers, and other variations ofprecursor web 20 can be varied as desired to produce desired functionalcharacteristics of the web 1.

[0077] If a woven precursor web 20 is utilized, the formation andstructure of second regions 4 can be very close to the same as thatexhibited by webs 1 formed from nonwoven webs. For example, if a wovenprecursor web 20 has warp or weft threads having sufficient elongationproperties and being predominantly oriented in a cross machinedirection, upon being processed by the apparatus 100 described above,the teeth 110 tend to separate the machine direction threads (eitherwarp or weft) and only urge out of plane the cross-machine directionthreads. Thus, the web 1 produced from a woven precursor web 20 can lookand feel very much like terry cloth fabric.

[0078] In preferred embodiments precursor web 20 is a nonwoven web inwhich there are minimal fiber-to-fiber bonds. For example, the precursorweb can be a nonwoven web having a pattern of discrete thermal pointbonds, as is commonly known in the art for nonwoven webs. In general,however, it is desirable to minimize the number and spacing of bondpoints so as to allow for maximum fiber mobility and dislocation at thesecond regions 4 of web 1. In general, utilizing fibers havingrelatively high diameters, and/or relatively high extension to break,and/or relatively high fiber mobility, results in better and moredistinctly formed second regions 4, specifically deformations 6.

[0079] Although web 1 is disclosed in preferred embodiments as a singlelayer web made from a single layer precursor web 20, it is not necessarythat it be so. For example, a laminate or composite precursor web 20having two or more layers or plies can be used. In general, the abovedescription for web 1 holds, recognizing that looped aligned fibers 8,for example, formed from a laminate precursor web would be comprised offibers from both (or all) layers of the laminate. In such a webstructure, it is important, therefore, that all the fibers of all thelayers have sufficient diameter, elongation characteristics, and fibermobility, so as not to break prior to extension and deformation. In thismanner, fibers from all the layers of the laminate may contribute to thetufted deformations 6. In a multilayer web, the fibers of the differentwebs may be mixed or intermingled in the deformation 6. The fibers donot protrude through but combine with the fibers in an adjacent web.This is often observed when the webs are processed at very high speeds.

[0080] Multilayer webs 1 can have significant advantages over singlelayer webs 1. For example, a deformation 6 from a multilayer web 1 usingtwo precursor webs 20A and 20B is shown schematically in FIGS. 18-20. Asshown, both precursor webs 20A and 20B contribute fibers to deformations6 in a “nested” relationship that “locks” the two precursor webstogether, forming a laminate web without the use or need of adhesives orthermal bonding between the layers. However, if desired an adhesive,chemical bonding, resin or powder bonding, or thermal bonding betweenthe layers can be selectively utilized to certain regions or all of theprecursor webs. In addition, the multiple layers may be bonded duringprocessing, for example, by extruding a film onto a nonwoven or cardingone layer of nonwoven onto a spundbond and thermal point bonding thecombined layers. In a preferred embodiment, the deformations 6 retainthe layered relationship of the laminate precursor web, as shown in FIG.18, and in all preferred embodiments the upper layer (specifically layer20A in FIGS. 18-20, but in general the top layer with reference to theZ-direction as shown in FIGS. 18-20) remains substantially intact andforms looped fibers 8.

[0081] In a multilayer web 1 each precursor web can have differentproperties. For example, web 1 can comprise two (or more) precursorwebs, e.g., first and second precursor webs 20A and 20B. First precursorweb 20A can form an upper layer exhibiting high elongation andsignificant elastic recovery which enables the web 20A to spring back.The spring back helps to laterally squeeze the base portion 5 of thedeformation 6 of both webs as shown in FIG. 18. The spring back orlateral squeeze also helps to secure and stabilize the Z-oriented fibersin the deformation 6. The lateral squeeze provided by precursor web 20Acan also increase the stability of the second precursor web 20B. Anexample of a multilayer web 1 being identical in material and processingexcept for the line speed is shown with respect to FIGS. 15 and 16.Multilayer web 1 as shown in FIGS. 15 and 16 includes a first precursorweb 20A comprised of spunbond PE/PP sheath/core nonwoven web made byBBA, Washougal Wash. The second precursor web 20B is comprised of athermal point bonded carded PET/Co-PET nonwoven web (50% 6 dpf PETWellman Type 204 made in Charlotte N.C. and 50% 6 dpf Co-PET KanematsuType LM651 made in Gastonia N.C. The second precursor web 20B can beloosely bonded to enable tufting so the lateral squeeze of the firstprecursor web 20A can also increase the stability of the secondprecursor web 20B. The multilayer webs 1 were both processed at a depthof engagement E of about 3.4 mm (about 0.135 inch). The multilayer web 1shown in FIG. 15 was processed at a slow speed, 3 meters per minute, andthe multilayer web 1 shown in FIG. 16 was processed at a high speed, of150 meters per minute. As can be seen, the fibers from the first andsecond precursor webs 20A and 20B in the deformation 6 in FIG. 16 (highspeed processing) are much more intermingled than those shown in FIG. 15(slow speed processing). The multilayer web 1 can be utilized as abody-contacting layer when used as a topsheet on a disposable absorbentarticle.

[0082] In a multilayer web 1 each precursor web can have differentmaterial properties, thereby providing web 1 with beneficial properties.For example, web 1 comprising two (or more) precursor webs, e.g., firstand second precursor webs 20A and 20B can have beneficial fluid handlingproperties for use as a topsheet on a disposable absorbent article, asdescribed more fully below. For superior fluid handling, for example,first precursor web 20A can form an upper layer (i.e., a body-contactingwhen used as a topsheet on a disposable absorbent article) and becomprised of relatively hydrophobic fibers. Second precursor web 20B canform a lower layer (i.e., disposed between the topsheet and an absorbentcore when used on a disposable absorbent article) comprised ofrelatively hydrophilic fibers. Fluid deposited upon the upper,relatively hydrophobic layer is quickly transported to the lower,relatively hydrophilic, layer. One reason for the observed rapid fluidtransport is the capillary structures formed by the generally alignedfibers 8, 18 of deformations 6. The fibers 8, 18 formdirectionally-aligned capillaries between adjacent fibers, and thecapillary action is enhanced by the general convergence of fibers nearproximal portion 5 of deformations 6.

[0083] It is believed that the rapid fluid transport is furtherincreased due to the ability of fluid to enter the web 1 via the voids10 created by deformations 6. This “lateral entry” capability and/orcapillary action, and/or the hydrophilicity gradient afforded by thestructure of web 1 makes web 1 an ideal material for optimal fluidhandling for disposable absorbent articles. In particular, a multilayerweb 1 can provide for even greater improvement in fluid handlingcharacteristics. In another embodiment, first precursor web 20A can becomprised of relatively soft fibers (e.g., polyethylene), while secondprecursor web 20B can be comprised of relatively stiff fibers (e.g.,polyester). In such a multilayer web 1, deformations 6 can retain orrecover a certain amount of height h, even after applied pressure. Thebenefit of such as structure, particularly when combined with ahydrophilicity gradient as described above (fibers can be renderedhydrophobic or hydrophilic by means known in the art), is a web 1suitable for use as a topsheet in feminine hygiene products thatprovides for superior fluid acquisition and superior rewet properties(i.e., reduced fluid movement back to the surface of the topsheet). Itis believed that the increased stiffness provided by the relativelystiff fibers of second precursor web 20B provide for increasedcompression resistant caliper (thickness) of the web, while therelatively soft fibers of first precursor web 20A provides for softnessat the web/skin interface. This extra caliper, together with the abilityof the distally-disposed portions 3 of deformations 6 to remainrelatively soft and relatively fluid free, results in a superior, soft,dry (and dry-feeling) topsheet for use in feminine hygiene products, aswell as baby diapers, adult incontinence articles, bandages, and thelike.

[0084] FIGS. 18-20 show representative schematic diagrams of possiblestructures for deformation 6, depending on the material properties ofprecursor webs 20A or 20B. Other structures, not shown, can be achieved,with the only limitation to various structures being the limitationsinherent in the material properties of the precursor webs.

[0085] Therefore, as can be seen from the above description, dependingon the precursor web 20 (or webs) utilized and the dimensionalparameters of rolls 102 and 104, including teeth 110, web 1 of thepresent invention can exhibit a wide range of physical properties. Theweb 1 can exhibit a range of texture subjectively experienced as rangingfrom softness to roughness, an absorbency ranging from non-absorbent tovery absorbent, a bulkiness ranging from relatively low bulk torelatively high bulk; a tear strength ranging from low tear strength tohigh tear strength; an elasticity ranging from non-elastic to at least100% elastically extensible, a chemical resistance ranging fromrelatively low resistance to high resistance, depending on the chemicalconsidered, and many other variable parameters generally described asshielding performance, alkali resistance, opacity, wiping performance,water absorptivity, oil absorptivity, moisture permeability, heatinsulating properties, weatherability, high strength, high tear force,abrasion resistance, electrostatic controllability, drape, dye-affinity,safety and the like. In general, depending on the elongation propertiesof the fibers of precursor web 20, the dimensions of apparatus 100 canbe varied to produce a web 1 having a wide range of dimensionsassociated with second regions 4, including the height h (as shown inFIG. 22), and spacing, including the area density of discrete secondregions 4).

[0086] Web 1 may be used for a wide variety of applications, includingvarious filter sheets such as air filter, bag filter, liquid filter,vacuum filter, water drain filter, and bacterial shielding filter;sheets for various electric appliances such as capacitor separatorpaper, and floppy disk packaging material; various industrial sheetssuch as tacky adhesive tape base cloth, oil absorbing material, andpaper felt; various wiper sheets such as wipers for homes, services andmedical treatment, printing roll wiper, wiper for cleaning copyingmachine, and wiper for optical systems; hygiene or personal cleansingwiper such as baby wipes, feminine wipes, facial wipes, or body wipes,various medicinal and sanitary sheets, such as surgical gown, gown,covering cloth, cap, mask, sheet, towel, gauze, base cloth forcataplasm, diaper, diaper core, diaper acquisition layer, diaper liner,diaper cover, base cloth for adhesive plaster, wet towel, and tissue;various sheets for clothes, such as padding cloth, pad, jumper liner,and disposable underwear; various life material sheets such as basecloth for artificial leather and synthetic leather, table top, wallpaper, shoji-gami (paper for paper screen), blind, calendar, wrapping,and packages for drying agents, shopping bag, suit cover, and pillowcover; various agricultural sheets, such as cow carpets, cooling and sunlight-shielding cloth, lining curtain, sheet for overall covering,light-shielding sheet and grass preventing sheet, wrapping materials ofpesticides, underlining paper of pots for seeding growth; variousprotection sheets such as fume prevention mask and dust prevention mask,laboratory gown, and dust preventive clothes; various sheets for civilengineering building, such as house wrap, drain material, filteringmedium, separation material, overlay, roofing, tuft and carpet basecloth, wall interior material, soundproof or vibration reducing sheet,and curing sheet; and various automobile interior sheets, such as floormat and trunk mat, molded ceiling material, head rest, and lining cloth,in addition to a separator sheet in alkaline batteries.

[0087]FIG. 21 is a photomicrograph of a terry cloth-like nonwoven fabricweb 1 made by the process of the present invention using a roll 104 asshown in FIGS. 9 and 10 and useful as a component of a disposableabsorbent article (as shown below in FIG. 23). The precursor web 20 usedfor the web 1 shown in FIG. 21 was a spunbond nonwoven having a basisweight of about 80 gsm, and comprising polyethylene/polypropylene(sheath/core) polyethylene/polypropylene (sheath/core) bicomponentfibers having an average diameter of about 33 microns. The web 1 of FIG.21 has about 24 deformations 6 per square centimeter and is folded withthe folded edge visible to show more clearly a plurality of spacedapart, tufted, looped deformations 6 having a plurality of looped,aligned fibers 8, each of which has an average fiber diameter of about18 microns.

[0088] A single deformation 6 is shown in FIG. 22 with dimensionsindicated. As shown in FIG. 10, for the web described with respect toFIG. 22, the void area 10 of tufted, looped, deformation 6 is typicallygenerally circular or oblong in shape, having a major dimension,referred to as height h, that can be at least 1 mm. In general, theheight is not considered to be critical to the operation of the web, butcan be varied depending on the desired end use of web 1. The height hcan be from 0.1 mm to about 10 mm or more. A web 1 formed from anonwoven precursor web 20 and having a look and feel of terry clothshould have a height h of about 1 mm to about 3 mm.

[0089] Table 1 below shows representative dimensions for representativeapparatus and webs made thereon. TABLE 1 Examples of ApparatusDimensional Parameters and Web Dimensions Avg. Fiber Avg. Tooth DiameterFiber Engagement Height Loop of Diameter Pitch (P) (E) (TH) heightPrecursor of Loop Sample <mm> <mm> <mm> (h) Web Fiber No. Precursor Web(inches) (inches) (inches) (mm) (μm) (μm) 1 80 gsm spunbond <1.5> <3.4><3.7> 1.07 33 18 PE/PP core/sheath (0.060) (0.135) (0.145) 2 80 gsmspunbond <1.5> <2.2> <3.7> 0.49 31 23 PE/PP core/sheath (0.060) (0.085)(0.145) 3 60 gsm spunbond <1.5> <3.4> <3.7> 1.10 23 14 PE/PP copolymer(0.060) (0.135) (0.145) 4 60 gsm spunbond <1.5> <3.4> <3.7> 1.41 28 15PE/PP copolymer (0.060) (0.135) (0.145)

[0090] In Table 1 above, all Samples are available from BBA Nonwovens,Simpsonville, S.C. Samples 1 and 2 are sold under the trade nameSoftex®. Samples 3 and 4 are sold under the trade name Sofspan 200®.

[0091]FIG. 23 shows in partial cut away plan view a catamenial article,specifically a sanitary napkin, having as one of its components a web 1of the present invention. In general, sanitary napkin 200 comprises abacksheet 202, a topsheet 206 and an absorbent core 204 disposed betweenthe topsheet 206 and backsheet 202 which can be joined about a theperiphery 210. Sanitary napkin 200 can have side extensions, commonlyreferred to as “wings” 208 designed to wrap the sides of the crotchregion of the panties of the user of sanitary napkin 1. Topsheet 206 ofsanitary napkin 200 comprises web 1 having deformations 6 on a bodyfacing side thereof. Alternatively, web 1 could be used with thedeformation 6 on side 12 opposite of the body-facing side and the secondside 14 being the body-facing side. This may enable the discontinuities16 to transport fluid into the deformations 6. Sanitary napkins,including topsheets for use as the body facing surface thereof, are wellknown in the art and need no detailed description of various alternativeand optional designs. Other catamenial articles, such as panty liners,interlabial devices, will also have similar structure as sanitarynapkins. It is noted that web 1 can be used as, or as a component of,one or more of a backsheet, core material, topsheet, secondary topsheet,or wing material. For example, web 1 could have multiple layers andcomprise the topsheet, secondary topsheet, core and/or backsheet ofhygiene product.

[0092] Web 1 can be utilized as an absorbent core in a hygiene product.The web 1 in an absorbent core may have a relatively high basis weightand/or be comprised of several layers. Specifically, an absorbent corecan comprise a fibrous web of randomly oriented fibers with respect toan X-Y plane. The core will comprise a first surface and a secondsurface. The first surface will comprise a plurality of discrete regionsof fiber reorientation. Each discrete region will have a linearorientation defining a longitudinal axis in the X-Y plane and willcomprise a plurality of fibers having portions reoriented in a directionsubstantially orthogonal to said X-Y plane.

[0093] Web 1 or a composite comprising web 1 can also be utilized as afecal material storage element. Web 1 can be utilized as a secondarytopsheet or sublayer when it is disposed under an apertured web or filmto accept and hold low viscosity feces or viscous bodily waste away froma wearer's skin after defecation. Embodiments of the present inventionhaving larger total three dimensional volume within the web or betweenthe deformations 6 generally provide a greater capacity for storage oflow viscosity feces. Absorbent articles employing such fecal materialstorage elements, or sublayers, are described in U.S. Pat. Nos.5,941,864; 5,957,906; 6,018,093; 6,010,491; 6,186,992; and 6,414,215,among others.

[0094]FIG. 24 shows in partial cut away perspective view a catamenialtampon 300 having as one of its components a web 1 of the presentinvention. In general, tampon 300 comprises a compressed absorbent core302 and a fluid permeable cover wrap 304 that covers absorbent core 302.Cover wrap 304 may extend beyond one end of absorbent core 302 to form askirt portion 306. A removal means, such as string 308 can be providedto facilitate removal of the tampon after use. Tampons, including coverwraps for use as the body contacting surface thereof, are well known inthe art and need no detailed description of various alternative andoptional designs. However, it is noted that web 1 can be used as, or asa component of, one or more of a cover wrap, absorbent core material, orremoval means material.

[0095] Another advantage of the process described to produce the webs ofthe present invention is that the webs can be produced in-line withother web production equipment or in-line with disposable absorbentarticle production equipment. Additionally, there may be other solidstate formation processes that can be used either prior to or after theprocess of the present invention. For example, portions of or all of aweb could be processed according to the present invention and thenapertured with a stretching process, such as one described in U.S. Pat.No. 5,658,639 to Curro et al. Alternatively, a material could be madeinto a composite through a variety of processes, such as one describedin U.S. Publication No. 2003/028,165A1 to Curro et al. or ring rolled,for example as in U.S. Pat. No. 5,167,897 to Weber et al. and thenprocessed according to the present invention. The resulting webs canthus exhibit the combined benefits of these multiple materialmodifications.

[0096] As can be understood from the above description of webs 1 andapparatus 100 of the present invention, many various structures of webs1 can be made without departing from the scope of the present inventionas claimed in the appended claims. For example, webs 1 can be coated ortreated with lotions, medicaments, cleaning fluids, anti-bacterialsolutions, emulsions, fragrances, surfactants. Likewise, apparatus 100can be configured to only form deformations 6 on a portion of the web 1,or to form varying sizes or area densities of deformations 6.

[0097] All documents cited in the Detailed Description of the Inventionare, in relevant part, incorporated herein by reference; the citation ofany document is not to be construed as an admission that it is prior artwith respect to the present invention.

[0098] While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed:
 1. A fibrous web (1) comprising a first region (2) andat least one discrete integral second region (4), the second region (4)having at least one portion being a discontinuity (16) exhibiting alinear orientation and defining a longitudinal axis (L) and at leastanother portion being a deformation (6) comprising a plurality of tuftedfibers (8, 18) integral with but extending from the first region (2). 2.The fibrous web of claim 1, wherein said web comprises a plurality ofdiscrete integral second regions.
 3. The fibrous web of claim 2, whereinsaid plurality of discrete integral second regions is uniformlydistributed on said fibrous web.
 4. The fibrous web of claim 1, whereinsaid fibrous web comprises a nonwoven web of substantially randomlyoriented fibers.
 5. The fibrous web of claim 2, wherein said fiberscomprise materials selected from the group consisting of cellulose,rayon, cotton, polyethylene, polypropylene, polyester, and blendsthereof.
 6. The fibrous web of claim 2, wherein said fibers comprisebicomponent fibers.
 7. The fibrous web of claim 2, wherein said fiberscomprise non-round fibers.
 8. The fibrous web of claim 1, wherein saidweb comprises at least 10 discrete integral second regions per squarecentimeter.
 9. The fibrous web of claim 1, wherein a portion of saidtufted fibers define an open void area internal to said second regions.10. A wipe comprising said fibrous web of claim
 1. 11. A soft, tuftedfibrous web (1) comprising substantially randomly-oriented fibers, theweb (1) comprising a first region (2) and a plurality of discrete secondregions (4), each of the second regions (4) having at least one portionbeing a discontinuity (16) exhibiting a linear orientation and defininga longitudinal axis (L) and at least another portion being a deformation(6), wherein the deformation (6) comprises fibers (8, 18) integral withbut extending from first region (2) and fibers (11) neither integralwith nor extending from first region (2).
 12. The fibrous web of claim11, wherein said fibers comprise materials selected from the groupconsisting of cellulose, rayon, cotton, polyethylene, polypropylene,polyester, and blends thereof.
 13. The fibrous web of claim 12, whereinsaid fibers comprise bicomponent fibers.
 14. The fibrous web of claim12, wherein said fibers comprise non-round fibers.
 15. The fibrous webof claim 11, wherein said web comprises at least 10 discrete integralsecond regions per square centimeter.
 16. A wipe comprising said fibrousweb of claim
 1. 17. A disposable absorbent article, said article havingat least one component comprising a fibrous web (1) comprising a firstregion (2) and a plurality of discrete integral second regions (4), thesecond regions (4) having at least one portion being a discontinuity(16) exhibiting a linear orientation and defining a longitudinal axis(L) and at least another portion being a deformation (6) comprising aplurality of tufted fibers (8, 18) integral with but extending from thefirst region (2).
 18. The article of claim 17, wherein said article isselected from the group consisting of a catamenial article, a tampon, ora diaper.
 19. The article of claim 17 wherein said fibrous web comprisesa topsheet of said article.
 20. The article of claim 17 wherein saidfibrous web comprises an absorbent core of said article.
 21. Amultilayer fibrous web (1) comprising at least an upper layer and alower layer, the multilayer fibrous web further comprising a firstregion (2) and a plurality of discrete integral second regions (4), thesecond regions (4) having at least one portion being a discontinuity(16) exhibiting a linear orientation and defining a longitudinal axis(L) and at least another portion being a deformation (6) comprising aplurality of tufted fibers (8, 18) integral with but extending from thefirst region (2) wherein the deformation (6) comprises at least theupper layer.
 22. The fibrous web of claim 21, wherein said upper andlower layers each comprise a nonwoven web of substantially randomlyoriented fibers.
 23. The fibrous web of claim 21, wherein said fiberscomprise materials selected from the group consisting of cellulose,rayon, cotton, polyethylene, polypropylene, polyester, and blendsthereof.
 24. An absorbent core comprising a fibrous web of randomlyoriented fibers with respect to an X-Y plane, said core comprising afirst surface and a second surface, a plurality of discrete regions offiber reorientation at least on said first surface, each said discreteregion having a linear orientation defining a longitudinal axis in saidX-Y plane, and comprising a plurality of fibers having portionsreoriented in a direction substantially orthogonal to said X-Y plane.25. The absorbent core of claim 24 wherein said plurality of discreteregions are only on said first surface.
 26. The absorbent core of claim24 wherein said discrete regions comprise fibers extending from saidfirst surface to said second surface.
 27. An absorbent articlecomprising a topsheet, a backsheet, and an absorbent core disposedbetween the topsheet and the backsheet, the absorbent core comprising afibrous web of randomly oriented fibers with respect to an X-Y plane,said core comprising a first surface and a second surface, a pluralityof discrete regions of fiber reorientation at least on said firstsurface, each said discrete region having a linear orientation defininga longitudinal axis in said X-Y plane, and comprising a plurality offibers having portions reoriented in a direction substantiallyorthogonal to said X-Y plane.